NCR Analysis

October 2008 – March 2009

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 NCR’s Processed - Comparison
250
221
203 198
200

145 144
NO. OF NCRs

150
124 119

100
92

50

0
Apr'06-Sep'06

Apr 08- Sep 08

Apr 07 - Sep 07
APR'05-SEP'05

Oct'08-Mar'09
Oct'05- Mar'06

Oct 06 - Mar 07

No. of NCRs reduced compared to previous periods. Positive Improvement. Oct 07 - Mar 08
COPQ for NCRs : Rs.22L 2 2
 NCR’s - PC Wise Breakup

• Encouraging trend in PC-1, PC-2 and LEMF.

• NCRs in Pre-manufacturing (PPE and DNA) area due to sub contracted
work at vendor’s place and discrepancy from raw material TC 3
NCR Summary- Area Wise
Area Oct07-Mar08 Apr'08-Sep'08 Oct'08-Mar'09
HFS 1 7 4 0
HFS 2A 1 3
3
HFS 2B 2 1
HFS 3A 1 3
13
HFS 3B 4 0
LFS 4 12 2
MFS-1 0 0 4
PPS 0 0 0
LEMF-Spl project NA NA 8
M/c shop 7 7 5
PC2 34 31 26
PFS 0 5 2
MFS-2 2 2 2
HFS 4A 2 2
8
HFS 4B 3 3
HFS 5A 2 2
11
HFS 5B 2 1
HFS 6A 0 0 1
HFS 6B NA NA 1
M/c shop 8 12 4

PC1 29 28 18
LEMF 81 54 33
Material control 14 6 11
PMG : NUCL +DEF 31 50 26
PMG -RCOG 6 11 14
PREMANUFACTURING 51 67 51
WE +NDT 0 0 0
STORES 0 0 0
HEAT TREATMENT 8 9 0
OTHERS 0 1 0
Grand Total 203 190 128
PMG : FPEX + CGPP (fab. at HZW)
0 8 16

Total no of NCR (Including Powai PMG FPEX, CGPP) 144

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 NCR CATEGORISATION-PROBLEM WISE
MAJOR NCR

No. of NCR's - No. of NCR's - No. of NCR's -

Sr. No. Type of NCR's
Oct.07-Mar.08 Apr.08-Sep.08 Oct.08-Mar 09

1 Material / Parts having deviation during in-process stage 21 30 44

2 Weld material not meeting specification 1 0 0
3 Repairs affecting base material 11 11 6
4 Usage of un-calibrated Intrument / Equipment 2 0 0
5 Heat-Treatment time-temperature chart deviation 8 9 2
Material rejection on account of poor-quality - on pressure parts /
6 0 0 4
load bearing parts
7 Major system failure 21 35 5
8 Dimensional deviations 92 90 69
9 Wrong weld edge preparation 3 7 2
10 Major deviations in setups 15 8 5
TOTAL 174 190 137

MINOR NCR
No. of NCR's - No. of NCR's - No. of NCR's -
Sr. No. Type of NCR's
Oct.07-Mar.08 Apr.08-Sep.08 Oct.08-Mar 09
1 Errors not affecting product quality 29 8 7

TOTAL 203 198 144

• 33% NCRs due to Material / Parts having deviation during in process stage. Out
of 44 NCRs, 11% due to supplier quality problems
• 48% NCRs are due to dimensional deviation. Out of 69 NCRs, 11% due to
supplier quality problems 5
 NCR Categorization-Problem / Root cause

Product category / Business group : Spl Projects (Defence)

Shop / Area wise major contributor
Number of
M/c Cause of NCR (Problem related) Problem root cause
NCR's LEMF PMG 2A 2B 3A HZMC LFS MFS-1
shop
- Improper Material Handling (1)
Material deviations at - Quality Issue of FIM material (1)
inprocess stage (4) - Damage occurred during machining (1)
- Operator mistake (1)
Repairs Affecting base - Operator mistake (3)
material (4) - Machine problem (1)
- Error in Pre approved drawing (2)
System failure (3) - W/o set up clearance welding is
progress (1)
39 8 5 12 2 1 3 3 1 4
- Wrong preparation / Interpretation of
PCR (10)
- Quality Issue of Supplier material (3)
- Process deviation (4)
Dimensional deviations (27)
- Too setting problem (3)
- Operator mistake (2)
- Quality Issue of FIM material (1)
- others (4)
Wrong WEP (1) - Wrong interpretation of drg (1)

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 NCR Categorization-Problem / Root cause

Product category / Business group : DNA- (Nuclear)

Number of
Cause of NCR (Problem related) Problem root cause
NCR's PMG LFS
- Improper Material Handling (1)
Material deviations at - Quality Issue of FIM material (1)
inprocess stage (2) - Damage occurred during machining (1)
- Operator mistake (1)
15 14 1 Heat treatment deviation (1) - Mistake at vendor place (1)

System failure (2) - Weld qualification not done (2)

- Quality Issue of Supplier material (4)
Dimensional deviations (5)
- Stringent Tolerance (1)
Minor NC (5) - TC discrepancy - FIM material (5)

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 NCR Categorization-Problem / Root cause
Summary of Root causes

Sr. Problem root cause No of % of

No. NCRs contribution
1 Quality issue of Supplier material / Subcontracted work 39 28 %
2 Operator Mistake 21 15 %
3 Wrong PCR Preparation/Interpretation 10 7.0 %
4 Improper handling of materials 10 7.0 %
5 Distortion 11 7.5 %
6 Tool setting problem / setting not verified 9
7 Quality Issue of FIM material 8
6 Indications after PWHT 6
7 Process deviation 6
8 Constraint joint 4
9 Wrong Interpretation of drg. / DCR not marked on drg. 4
10 Misc Causes 16

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Thank You